2004 Hyundai Terracan Owner's Manual

DO-IT-YOURSELF MAINTENANCE 6-17
G160A01A-GAT CHECKING CLUTCH PEDAL FREE-PLAY With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal freeplay. The freeplay should be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
SSA6160A
6 ~ 13 mm (0.24 ~ 0.51 in.)
G170A01A-GAT CHECKING BRAKE PEDAL FREE-PLAY With the engine off, press down on the brake pedal several times to reduce the vacuum in the brake booster. Then, using your hand, press down slowly on the brake pedal until you feel a change in resistance. This is the brake pedal freeplay. The freeplay should be within the limits speci- fied in the illustration. If it is not, have it inspect- ed by your Hyundai dealer and adjusted or repaired if necessary.
SSA6170A
3 ~ 8 mm (0.12 ~ 0.31 in.)
G150A01A-GAT CHECKING STEERING WHEEL FREEPLAY To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Use very light finger pressure and be sensitive to changes in resistance that mark the limits of the freeplay. If the freeplay is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
G150A01HP
Maximum
30 mm (1.18 in)

DO-IT-YOURSELF MAINTENANCE
6-18
G200A01A-AAT CHECKING AND REPLACING FUSES Replacing a Fusible Link A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness. (This could be caused by a short in the system drawing too much current.) If this ever happens, have a Hyundai dealer determine the cause, repair the system and replace the fusible link. The fusible links are located in a relay box for easy inspection.
G200A01HP
Bad
Good
Belt routing should also be checked to be sure there is no interference between the belts and other parts of the engine. After a belt is re- placed, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.
G190A01A-GAT CHECKING DRIVE BELTS Drive belts should be checked periodically for proper tension and adjusted if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if necessary. Diesel (2.5 TCI)
G190D01HP
G190D02HP
Gasoline
Generator pulley
Idler pulley Water pump pulley
COMP.pulley Autotensioner
Crankshaft pulley
Diesel (2.9 CRDi)
Crankshaft pulleyCOMP. pulley
Generator pulley Power steering pulley
Idler pulley Tension pulley
COMP. pulley
Power steering pulley
Water pump pulley Tension pulley Power steering pulley
Crankshaft pulleyTension pulleyGenerator pulley
Tension pulley
Tension pulley
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE You need a helper to check the brake pedal clearance. With the engine running, have your helper press down on the brake pedal several times and then hold it down with a force of about 490N (50 kg, 110 lbs). The brake pedal clear- ance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance is not within the limits specified in the illustration, have it inspected by your Hyundai dealer and adjust- ed or repaired if necessary.
SSA6180A
71 mm (2.80 in.)

DO-IT-YOURSELF MAINTENANCE 6-19
AXA6201B
3. Be sure to check all other fuses even if you find one that appears to have burned out.
4. Replace the blown fuse by pressing a new
fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuse clip repaired or replaced by a Hyundai dealer. If you do not have a spare fuse, you may be able to borrow a fuse of the same or lower rating from an accessory you can tempo- rarily get along without (the radio or cigarette lighter, for example). Always remember to replace the borrowed fuse.
1. Turn off the ignition and all other switches.
2. Open the fuse box and examine each fuse.
Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in the relay box to simplify this operation).
Good
G200B03YBurned out
CAUTION: A burned-out fuse indicates that there is a
problem in the electrical circuit. If you re-place a fuse and it blows as soon as the accessory is turned on, the problem is seri- ous and should be referred to a Hyundai dealer for diagnosis and repair. Never re- place a fuse with anything except a fuse with the same or a lower amperage rating. A higher capacity fuse could cause damage and create a fire hazard.
G200B01HP-GAT Replacing Accessory Fuses
G200B01HP
The fuse box for the lights and other electrical accessories will be found under the dashboard on the driver’s side. Inside the box you will find a list showing the circuits protected by each fuse.If any of your car’s lights or other electrical accessories stop working, a blown fuse could be the reason. If the fuse has burned out, you will see that the metal strip inside the fuse has burned through. If you suspect a blown fuse, follow this procedure:
CAUTION: When replacing a fusible link, never useanything but a new fusible link with the same or lower amperage rating. Never use a piece of wire or a higher-rated fusible link. This could result in serious damage and create a fire hazard.

DO-IT-YOURSELF MAINTENANCE
6-20
G220B01A-AAT Checking Engine Cooling FanThe engine cooling fan should come on auto- matically if the engine coolant temperature is high. G220C01A-AAT Checking Condenser Cooling FanThe condenser cooling fan should come on automatically whenever the air conditioning is in operation. G230A03A-AAT POWER STEERING FLUID LEVEL
G230A01HP
Gasoline or Diesel (2.5 TCI)
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in the area.
o Keep children away from the area. G210B01A-AAT Checking the BatteryKeep the battery clean. Any evidence of corro- sion around the battery posts or terminals should be removed using a solution of household bak- ing soda and warm water. After the battery terminals are dry, cover them with a light coat- ing of grease. G220A01A-AAT CHECKING ELECTRIC COOLING FANS WARNING: The cooling fan is controlled by engine cool- ant temperature and may sometimes oper- ate even when the engine is not running. Use extreme caution when working near the blades of the cooling fan, so that you are not injured by a rotating fan blade. As the en- gine coolant temperature decreases the fan will automatically shut off. This is a normal condition.
G210A01A-AAT CHECKING THE BATTERYWARNING: Batteries can be dangerous! When working with batteries, carefully observe the follow- ing precautions to avoid serious injuries. The fluid in the battery contains a strong solu- tion of sulfuric acid, which is poisonous and highly corrosive. Be careful not to spill it on yourself or the car. If you do spill battery fluid on yourself, immediately do the following:
o If battery fluid is on your skin, flush the
affected areas with water for at least 15 minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your eyes with water and get medical assistanceas soon as possible. While you are being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water.
o If you swallow battery fluid, drink a large quantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink vegetable oil. Get medical assistance as soon as possible.
While batteries are being charged (either by a battery charger or by the vehicle’s alternator), they produce explosive gases. Always observe these warnings to prevent injuries from occur- ring:

DO-IT-YOURSELF MAINTENANCE 6-21
G350A01HP-GAT BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.5 TCI))
E090A01HP
The fuel system should be bled to remove air as described in the illustration if the fuel supply is exhausted during travel, when the fuel filter is replaced, or if the vehicle is not used for a long time.
G240A01A-AAT POWER STEERING HOSESIt is suggested that you check the power steer- ing hose connections for fluid leakage at regular intervals. The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn spots. Deterioration of the hose could cause premature failure.
NOTE: Do not start the engine when the powersteering oil reservoir is empty.
2. Pump the hand pump until there are no more
bubbles in the fuel coming out of the air plug. When doing this, place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air bleed bolt when there are no more bubbles in the fuel.
4. Continue pumping until the hand pump be- comes stiff.
5. Finally, check to be sure that there is no leakage of fuel.If in doubt, consult your nearest authorizedHYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
E090A02HP
1. Loosen the air bleed bolt at the top of the fuel
filter with a flat-bladed screwdriver or equiva- lent.
The power steering fluid level should be checked daily. To check the power steering fluid level, be surethe ignition is "OFF", then check to make cer- tain that the power steering fluid level is be- tween the "MAX" and "MIN" level markings on the fluid reservoir. NOTE: Grinding noise from the power steering pump may be heard immediately after the engine is started in extremely cold condi- tions (below - 20°C). If the noise stops dur- ing warm up, there is no abnormal function in the system. If is due to a power steering fluid characteristic in extremely cold condi- tions. Recommended Fluid Use PSF-3 type fluid.
G230A02HP
Diesel (2.9 CRDi)

DO-IT-YOURSELF MAINTENANCE
6-22
G350B01HP-GAT
BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.9 CRDi))
The fuel system should be bled to remove air as described in the illustration if the fuel supply is exhausted during travel, when the fuel filter is replaced, or if the vehicle is not used for a long time.
1. Pump the hand prime pump with your hand for one minute(about 20~30 times).
2. Turn the ignition key to the "START" posi- tion and release it 2~3 times shortly until the engine starts.
CAUTION:Do not hold the ignition key in the "START"position for more than 15 seconds. Doing so may cause the engine and the injection pump to damage.
G350A01HP
E090A02HP
2. Operate the hand pump slowly 6 or 7 times in order to force the water out through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air bleed bolt and bleed the air. (Refer to "Bleeding the fuel system")
5. Check to be sure that the warning lamp
illuminates when the ignition key is turned to "ON", and that it goes off when the engine is started. If in doubt, consult your nearest authorized HYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding thefuel system.
(2) Be sure to carefully wipe away any water drained out in this manner, because thefuel mixed in the water might be ignited and result in a fire.
G300A01HP-GATREMOVAL OF WATER FROM THE FUEL FILTER (FOR DIESEL ENGINE (2.5 TCI))
E100A01HP
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter.
(2) Be sure to carefully clean away any fuel
which spilled onto nearby parts coming out of the air bleed bolt, because such
accumulations of fuel might ignite andcause a fire.

DO-IT-YOURSELF MAINTENANCE 6-23
G260A01HP-GAT
REPLACING HEADLIGHT BULBS Before attempting to replace a headlight bulb,
be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach the
headlight bulbs so they may be changed. Besure to replace the burned-out bulb with one of the same number and wattage rating. WARNING:Be sure to carefully wipe away any water
drained out in this manner, because the fuel mixed in the water might be ignited and result in a fire.
NOTE:The driver's side headlight bulb can be
changed after lifting the engine coolant res-ervoir by hand.
CAUTION:Keep the lamps out of contact with petro-
leum product, such as oil, gasoline, etc.
G260A01HP Replacement instructions:
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its plastic base, avoid touching the glass.
3. Disconnect the power cord from the bulb base in the back of the headlight.
4. Push the bulb spring for removing the head-
light bulb.
5. Remove the protective cap from the re- placement bulb and install the new bulb bymatching the plastic base with the headlight hole. Retighten the bulb spring and recon- nect the power cord.
6. Use the protective cap and carton to dis- pose of the old bulb.
7. Check for proper headlight aim. G270A02Y-AAT HEADLIGHT BULB
G270A01HP
G300B01HP-GAT REMOVAL OF WATER FROM THE FUEL FILTER
(FOR DIESEL ENGINE (2.9 CRDi))
G300A01HP
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter.
2. Tighten the drain plug when water no longer
comes out.
3. Check to be sure that the warning lamp illuminates when the ignition key is turned to "ON", and that it goes off when the engine is started. If in doubt, consult your nearest authorizedHYUNDAI dealer.

DO-IT-YOURSELF MAINTENANCE
6-24 6. Draw the vertical line (through the center of
each headlight) and the horizontal line (through the center of each headlight) on the aiming screen.
(1) Horizontal line dimension from ground :Low Beam : 894 mm (35.1 in.)
High Beam : 839 mm (33 in.)
(2) Distance between each vertical line : Low Beam : 1,316 mm (51.8 in.)
High Beam : 1,076 mm (42.4 in.)
And then, draw a parallel line at 38 mm (1.50 in.) under the horizontal line in case of adjusting the low beam or at 21 mm (0.83 in.) under the horizontal line in case of adjusting the high beam.
7. Adjust each cut-off line of the low beam to the parallel line with a phillips screwdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to
the each vertical line with a phillips screw-driver - HORIZONTAL AIMING.
G290A01HP-GAT
HEADLIGHT AIMING ADJUSTMENT
G290A01HP
Horizontal aiming (Low Beam)
Vertical aiming (Low Beam)
Before performing aiming adjustment, make sure of the following.
1. Keep all tires inflated to the correct pres- sure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down sev-eral times. Place vehicle at a distance of 3m (118.1 in.) from the test wall.
3. See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, andspare tire, jack, and tools). Have the driver or equivalent weight placed in driver's seat.
4. Clean the headlight lens and turn on the headlight.
5. Open the hood. Vertical aiming (High Beam)
Horizontal aiming(High Beam)
G270A02HP
WARNING: The halogen bulb contains gas under pres- sure and if impacted could shatter, resulting in flying fragments. Always wear eye pro- tection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installing in a headlight. Re- place the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.